Process of and apparatus for forming compound ingots.



1. SLATTERY.

PROCESS 0F AND APPARATUS FOR FORMING C OMPOUND INGOTS.

APPLICATION FILED JAN.

Patented Feb. '22, 1916.

3 SHEETS-SHEET I.

J. SLATTERY.

PROCESS 0F AND APPARATUS FOR FORMING COMPOUND INGOTS.

APPLICATION FILED JAN. s. 1915.

1,172,747. Patented Feb. 22,1916.

3 SHEETS-SHET 2.

1. SLATTERY. PROCESS 0F AND APPARATUS FOR FORMING COMPOUND INGOTS.

APPLICATION FILED 1AN.5. 1915.

1,172,747. l Patented Feb.22,1916.

3 SHEETS-SHEET 3.

lof molten metal, retards the JOHN SLATTERY, 0F CHROME, NEW JERSEY.

PROCESS OF AND APPARATUS FOR FORMING COMPOUND INGOTS.

p Specification of Letters Patent.

Patented Feb. 22, 1916.

Application led J' anuary 5, 191.5. Serial N o. 554.

To all whom t may concern:

Be it known that I, JonN SLATTERY, citizen of the United States of'America, and

a resident of Chrome, county of Middlesex,

and State of New Jersey, have invented` certain new and useful Improvements in Processes of and Apparatusl for Forming Compound Ingots, of which the following is a specification.

My invention relates to processes and apparatus for forming compound ingots, particularly ingots composed of layers of low carbon and high carbon steel, united; and the invention pertains particularly to that class of such processesV and apparatus wherein a septum is provided, within the ingot mold, which septum, without absolutely preventing contact of the two grades iow of the two metals toward each other to such extent that 'the'"metals unite with very little mixing.

The septum is commonly. of metal, oft1 a melting point and nature such that it will be melted by the molten metal and so 'will bel incorporated practically indistinguishably into the metal of the resulting compound ingot.

'le such processes have been proposed heretofore, yet-so far as I am informed, practical diliculties have prevented their use, atleast to any considerable extent, andparticularly in the formation of large ingots such as are required in the production of armor plate, rail steel, vault or safe steel, rolling mill rolls, etc.. These practical'dih'iculties are overcome by the process and apparatus herein described.

According to one method ofv carrying out my invention the septum employed is, preferably, va structure composed of a series of plates hung vertically within ythe mold in such manner as to provide staggered openings for the flow of the two metalsptogether,` the tortuous nature of the passages formed by these staggered .openings suicing to so retard the How of themetals toward each other to such extent that the metals unite in the molten statewith very little mixing, the septum becoming incorporated with .the said metals as they solidify. But otherfcon-` structions of septa presenting staggeredl openings for the 'ow of. the two metal's'together may be employed without departing from my invention, and I do not limit my the sep-tum prematurely,

self to the use of. septa presenting tortuous passages for the flow of the molten metals toward each other.

That side of the mold which is to receive the high carbon steel is preferably provided with a runner or runners of 'refractory material, such as fire brick, extending from near the bottom of the mold upward, and having lateral openings for the flow of the molten metal into the mold; this construet1on being employed to. prevent the very iuidAhigh carbon steel from melting down and from melting down the sides of the mold. Both sides of the mold may be provided with such runners, but in general it is not necessary to provide the low carbon steell side of the mold with such a runner with lateral openings. I prefer to pour the low carbon steel side of the mold from; the top, using a head box to control and direct the flow of the molten metal, and preferably I also employ av similar head box for the supply of molten high carbon steel to the said runner for the high carbon steel side of the mold, regulating the How ofi-the steel through these head boxes so that the molten metals are kept at approximately equal heights on the` two sides of the septum during the pourmg. In

lthis way, the incoming hot metal is-kept Thismanner of pouring the ingot, e.,

pouring it in such manner that the incoming hot metal overlies the colder metal already within the mold, tends to prevent piping in the ingot, since the more fluid metal above tends to ll any pipe formed below. These matters will be explained atl greater length hereinafter.

My invention consists in the novel process of forming compound metal ingots,

comprising the flow of both bodie of molten 'metal into the mold from the top, and the regulation of the rate `of flow with reference lto the rate7 of meltingA of the septum;

in the combination of an ingotmold having a septum and .pouring heads; 1n an ingot in section.

mold having on one side a runner with lateral openings into the mold; in the construction ofthe septum, and in various other features all as hereinafter described and particularly pointed out in the appended claims.

In the accompanying drawings I illustrate more or less diagrammatically, apparatus which may be employed in carrying out my invention.

In said drawings, Figure 1 shows a side elevation of an ingot mold, and head boxes therefor, all constructed in accordance with the apparatus portion of my invention, and adapted for carryingout the process portion of my invention. Fig. 2 shows a top view of the mold itself, and of the septum therein. Fig. 3 shows a vertical section 'of the ingot mold onthe line .va-m of Fig. 2, and also shows the head boxes above the mold, one of these head boxes being shown Fig. 4 shows a vertical section of the ingot mold and head boxes on the line g/-y of Fig. 2. Fig. 5 shows a vertical section of an alternative form of mold, having a runner with lateral openings for each of the two bodies of molten metal. Fig. 6 shows a top view of an ingot mold of generally circular form, and illustrates the application of my invention to the formation of combined ingots wherein one grade of metal surrounds the other grade of metal.

In the drawings numeral 1 designates the ingot mold, 2 a floor plate upon which the same may rest, 3 a removable mold top, 4 a lateral extension of the moldI to receive the sectional runner 5, and 6 the septum, composed in the main of a series of staggered plates 6a, as indicated particularly in Fig. 2. Suitable means, such for example, as cleats 7 provided on the floor plate 2, and wedges 8 adapted to be driven between the mold and `Ithese-5: gpl/eats, are provided for holding the mold iii place on the Hoor plate. Suitablel means, such for example as wedges 9 secured tothe mold top 3 and adapted to fit between lugs 10 on the sides of the mold, are `provided for centering the mold top with reference to the mold; and suitable means, lsuch as yokes 11 and wedges 12 engaging lugs 13 onthe sides of the mold and mold top, are provided for holding the mold top in place. The details of construction of these parts are familiar and require no further mention.

As previously stated, the septum is composed in the main of staggered plates 6, these plates being held in proper relative relation by slotted plates 6b in the slots of which plates 6b, the vvertical plates 6"L are held tightly, as by close frictional engagement. Suitable means may be provided for hilding the septum 6 down; f5.6., for preventing it from owing in the molten metal. To this end I have indicated the mold top 3 as' provided with an internal flange 14 which will rest upon the top of the uppermost plate 6", pressing the septum down with suflicient firmness to prevent that septum from being displaced by surging of the molten metal against it.

The refractory runner 5 is formed in sections 53, as shown particularly in Fig. 3; these sections having registering central passages 15 and lateral orifices 16 leading into the interior of the mold, these orifices being staggered preferably, as indicated in Fig. 4. By making each of these openings 16 of relatively small height, and staggering them, I provide ample strength for the runner sections 5a, without interrupting in any way the continuous flow of the molten` metal from the runner into Vthe mold. As heretofore stated by me, various plans have been proposed heretofore for the formation of combined ingots by pouring molten metal of different grades on opposite sides of a septum; but, so far as I am informed, without success, at least where the formation of large ingots of metal of such high melting point as steel is concerned. According to one such method, the ingot mold is to be divided by two perforated partitions, set into the mold, and spaced somewhat apart one from the other, means being provided for running molten metal from below into the mold on the two sides of the double partition thus formed. According to my experience, this method of forming compound ingots cannot be successfully carried out, at least when the septum is intended to meltv and become incorporated with the cast metal, for since the molten metal enters the mold from below, the first metal that comes into the mold stays on top, rising as more molten metal enters the mold. The result must be, inevitably, that the septum plates will be melted away inv the lower part of the mold only, the remainder of the septum plates not being melted at all, and probably, not combining vat all with the cast metal; while, on the other hand, the lower portions of these septum plates will be melted so quickly that the two incoming streams of hot metal willr mingle greatly, thus defeating the purposey beneath, piping is very apt to start in the top of the ingot without any materialtendency toward the filling of pipes, if formed, by the more iuid metal beneath; and furthermore, the upper metal of the ingot is icient rapidity throughout oered by apt to shrink away from the sides of the mold.

According to another formerly proposed method, the mold is -to be divided internally by two imperforate plates spaced apart, and, apparently, of sucient thickness to resist fusion by the molten metal lying against them until the mold is substantially filled; at which time the partition plates mentioned are supposed to melt down permitting the two grades of molten metal to flow together. It is not stated how the mold is to be poured, z'. e., whether from above or from below. Obviously itwould be very diiicult to provide dividing plates of just the right material and just the right thickness to resist the fusing tendency of the molten metal until the mold is practically full, .and then to melt down with suftheir length to permit substantial uniform union of the two molten metals while those metals are still hot enough to unite, and yet not so fluid as to become mingled indistinguishably. In fact, such a method forms, artificially, an exaggerated pipe, just what is most to be avoided. It is impossible to believe that by such a method, compound steel ingots could be produced in which the two grades of steel are united with substantial uniformity throughout the length of the ingot, and without being mixed to such an extent that there could hardly be any difference between the metal on one side of the ingot and the metal on the other.

Now according to my invention the mold is poured, on both sides of the septum, from the top, but in such manner that the molten metals are septum, and thereby are prevented from cutting the sides of the ingot mold and from melting the septum prematurely. To the contrary, the molten metal enters the mold somewhat quietly, the lower. carbon steel, in particular, entering the mold in a solid stream, which spreads out, the metal which first enters the mold remaining at the bottom of the mold, each increment of the molten metal remainingsubstantiallyatthe level at which it encounters the molten metal already within the mold. Of course, the two molten metals pass through the tortuous passages of the septum and contact one with the other, as is intended. But the resistance these tortuous passages to the flow of the molten metal is such that no considerable mixture of the two grades of metal with each other occurs. first enter' the mold soon melt down the portions of the septum plates. immersed in such metals; but by the time this has occurred the molten metal, up to the level at which the melting occurs, has become relatively quiet,

prevented from washing down along the sides of the ingot mold and of the` The metals which and moreover has already begun to solidify,

at least to the extent of becoming pasty, and so little or no mixing of the two grades of metal occurs; and this action progresses upwardl along the septum as the mold is filled; the septum resisting the tendency of the molten metal to flow together and mix for a time, and then, as the septum is melted, permetal within them passes down into the ingot mold. The discharge opening 19 of the pouring box 17, used for the lower carbon steel, is preferably provided with a spout 21 of such length as may be found most suitable for the particular grade of steel'and size of the ingot to be made. Such an elongated opening 19 gives to the downwardly directed stream of molten metal, a solid stream, as distinguished from a spray stream; and thereby the molten metal is prevented from spreading out, before it reaches the top of the molten metal already in the ingot mold, and so is prevented from washing down the sides of the ingot mold and of the septum; furthermore, being in a solid stream, it retains its heat much better, and is less affected by the air. Proper regulation of the rate of flow of the molten metals may be obtainedv by regulating the height to which the pouring boxes are kept filled during the progress of the pouring; and by regulating the size or diameter of the openings 19 and 20; and of course, it is practicable for the attendants to obstruct the openings 19 and 20 temporarily by clay plugs or the like, in the well known manner, if further restriction is required.

In general, itpis unnecessary to provide pouring head 18 for the high carbon steel with a spout such as the spout 21 of the pouring head 17 fory the reason that the pouring head 18 may be located a short distance only above the runner 5, and that runner itself prevents the molten metal from spreading out, and forces it to enter the mold quietly. The pouring head 17 may be suspended from above, and its spout 21 may be of such length that such spout will be vwell within the mold, when the pouring is started, the molten metal then having only a short distance to fall; and as the level of the molten metal rises in the mold the pouring head 17 may be raised. To prevent the fioor plate from being eaten away by the molten metal entering through pourin head 17, a body 22 of refractory materia may be provided purpose head boxes, or'

the characteristic of in this floor plate to receive the impact of the first of the molten metal. This refractory body 22 is, of course, renewable. However, and as indicated particularly in Fig. 5, runners 5 may be provided on both sides of the septum.

The inside of the mold top 3 is protected, preferably, by a covering 23 of sand or fire clay or the like.

Not only is the septum herein illustrated and described relatively cheap and easy to make, but it is the first septum of which I am aware, in which adequate provision is made for expansion of the septum itself, with `rise of temperature without disturbance of the position of the septum in the mold, and without warping of the septum. l/Vhile the spacers 6b hold the septum plates 6a quite firmly, yet extension of the plates 61- through the holes of the upper spacer 6* is permitted, this upper plate 6b being held in place by the iiange 14 of the mold top 3.

My invention is not restricted to the formation of rectangular ingots. It is equally applicable to the formation ofingots of circular or other non-rectangular cross section.

In Fig. 6 I show an ingot mold of a corrugated exterior contour, the general form of the ingot being cylindrical. 6a" designates the septum, and 5 runners for the mold similar to the runner 5 of Figs. 141 inclusive. 6a designates the staggeredplates of the septum. and 6" the slotted plates holding plates 6a in place.

From what has been said above, it will be clear that not only will this 'process produce combined ingots of substantially uniform quality from one end to the other, and with perfect union obtained between the two grades of metals without material diffusion of one metal into the other, but also that! there is relatively little tendency towardpiping, as compared with ingots formed in othery ways; for, since the metal poured first solidies first, and in the lower portion of the mold, the still highly fluid metal above tends to flow down into and fill any pipes formed in the solidifying metal below.

What I claim is v 1. The herein described method of casting compound metal ingots, which consists in flowing molten metal from diderent sources, into a suitable mold on opposite`sides of a septum dividing that mold, each stream of molten metal entering the mold from above and in the form of a quiet stream which spreads out with little disturbance of the molten metal beneath, each increment of the molten metal remaining substantially at the level at which it encounters the molten heat of the molten metal melting the septum f upward progressively and causing its mamolten metal with reference to the rate of melting of the'septum to preserve substantial integrity of each portion of the septum until the molten metal in contact with such portion has cooled to such extent that. little diffusion of the two bodies of molten metal in one another will occur upon the melting of that portion of the septum.

2. The herein described method of casting compoundmetal ingots, which consists in flowing molten metal from different sources into a suitable mold on opposite sides of a septum dividing that mold, but affording restricted passages for contact of the two bodies of molten metal with one another, both streams of molten metal entering the mold from above, and mingling to some extent by passage vthrough the restrictedpassages of theseptum, and by the heat of the molten metal melting the septum upward progressively and causing its material. to combine with the cast metal, and regulating the flow of both streams of molten metal with reference to the rate of melting of the septum to preserve substantial integrity of each portion of theseptum until the molten metal in contact with such portion has cooled to such extent that little diffusion of the two bodies of molten metal in one another will occur upon the melting of that portion of the septum.

3. Apparatus for forming compound metal ingots comprising an ingot mold having a septum dividing its interior, in combination with means for introducing molten metal of different grades into the mold on opposite sides of said septum, botlrof such molten metal supply means comprising means for delivering the rmolten metal. into the mold from above and for delivering such molten metals in quiet streams.

4. Apparatus for forming compound metal ingots comprising an ingot mold having a septum dividing its interior, in combination with pouring heads having bottom openings adapted to discharge two different bodies of molten metal, at least one of them in the form of a quiet stream into said ingot mold on opposite sides of said septum and lnot directed thereagainst.

Apparatus .for forming compound metal ingots comprising an ingot mold having a septum dividing its interior, in combination with means for introducing molten metal of different grades into the mold from above on opposite sides of said septum and not directed thereagainst, one of said molten metal introducing means being a pouring head having a bottom spout.

6. Apparatus for forming compound 'metal ingots comprising an ingotmold having a septum dividing its interior, and having, on one side of said septum, a runner having a longitudinal passage with lateral How means leading from such longitudinal passages into the mold, such lateral flow means extending continuously from near the bottom of the mold to near the top thereof.

7. Apparatus for forming compound metal ingots comprising an ingot mold having a septum dividing its interior, and having, on one side of said septum, a runner h-aving a longitudinal passage with a series of lateral staggered openings leading from such passage to the mold, such series of openings extending from near the bottom of the mold to near the top thereof.

8. An ingot mold having on one side a runner having a longitudinal passage with ka series of lateral staggered openings leading from such passage to the mold, such series of openings extending from near the bottom of the mold to near the top thereof.

9. A mold septum comprising bodies arranged in a plurality of rows, the bodies in each row separated one from another and the bodies of one row opposite the spaces between the bodies of another row, in combination with means holding suchl bodies in such spaced arrangement.

10. A mold septum comprising bodies arranged in a plurality of rows, the bodies in each row separated one from another and the bodies of one row opposite the spaces .between the bodies of another row, in combination with means holding such bodies in such spaced arrangement, and affording opportunity for longitudinal expansion of said bodies. A

11. A mold septum comprising-a plurality of bodies spaced apart one from another, -1n combination with spacing means therefor, comprlsing a spacing member having openings through whichsuch bodies pass, such spacing member adapted to permit longitudinal expansion of said members.

12. The combination with an ingot mold of a septum therein having a plurality of tortuous passages through it for the flow of molten metal.` l Y 13. The combination with an ingot mold, of a septum therein comprising a plurality of bodies spaced one from another, spacing means for said bodies and a mold top having means engaging said spacing means and thereby holding the septum in place.

14. The combination with an ingot mold, of a septum therein comprising a plurality of bodies spaced one from another, spacing means for said bodies and a mold top having 'an inwardly projecting ange engaging said spacing means and thereby holding the septum in place.

l5. Apparatus. for forming compound metal ingots comprisingan ingot mold having a septum dividing its interior, in combination with means for flowing molten metal from different Vsources into said mold on opposite sides of said septum, and not directed thereagainst, and for vsupplying such molten metal progressively to the vtop of moltenmetal already within the mold, such molten metal supply means comprising means for restricting the rate of iiow of molten metal into the mold. l

16. Apparatus for forming compound metal ingots comprising an ingot mold havv ing a septum dividing its interior, in combination with means for introducing molten metal of different grades into the mold on opposite sides of said septum and not directed thereagainst, said molten metal supply means each comprising means affording a substantially constant rate of flow of the molten metal into the mold.

In testimonyy whereof I have signed this specification in the presence of two subscrib- JOHN SLATTERY. Witnesses H. M. MARBLE, PAUL H. FRANKE.

'ing witnesses. 

